As part of the Electrical Apparatus Service Association (EASA) 2024 Convention in Las Vegas this June, Paul Rossiter, President of Energy Management Corporation (EMC) was named the newest Chairman of the Board after previously serving as the vice chairman for the last year. 

In his speech to the Board of Directors on Wednesday, Rossiter promoted “Powering the Future” during the last day of the EASA Convention.  

“All EASA members need to be ready to compete and win in the future of this industry,” Rossiter said. “Today, the three-phase AC electric motor we all know so well looks remarkably similar to the design that [Nikola] Tesla patented in 1888…Due to an increase in electrification, we are seeing motors in more places than we thought possible 15-20 years ago, and that is the beauty of the future. It’s ever changing and advancing.” 

Rossiter succeeds former Chairman Sean McNamara, who is a Regional Operations Manager with Komatsu in Brisbane, Australia. McNamara joined with a long line of past EASA Chairmen and was presented by Rossiter with a plaque and pin commemorating his service. 

Since 2013, Rossiter has led EMC in an executive role and was elevated to President of the company in 2018. Rossiter’s leadership has kept EMC going strong for six years and running, including keeping the company stable and profitable through the COVID-19 pandemic. He was named one of Utah Business Magazine’s 40 Under 40 in February of 2024. 

EMC’s imprint on the electrical energy industry goes back to 1979, and portions of the company have been running strong for over a century. The company has been a leader in the work of variable frequency drives (VFDs), electric motors, and backup generators with its three-fold mission of safety, reliability, and energy efficiency. 

Blockages are a problem encountered by wastewater systems all over the world. As more trash enters the wastewater system, it leads to clogs that must be dealt with. The National Association of Clean Water Agencies (NACWA) reported on studies that showed the rise of flushable wipes poses a massive problem to wastewater systems. 

These wipes don’t break down enough to prevent clogs. These wipes, along with other trash and debris, can lead to overflows, runoff, and other disastrous and expensive issues. Just these wipes alone are estimated by the NACWA to add $441 million per year in operating costs at clean water utilities. 

This problem has often been dealt with through shredders, grinders, and macerators, meant to tear these blockages apart and keep water moving. This is often not enough. This is where many wastewater facilities turn to deragging technologies, also called anti-ragging or anti-clogging. These technologies can help to keep systems running smoothly. 

Deragging Devices 

A typical deragger functions by using the pumps and waterflow itself to help break up blockages. The deragger reverses the pump and water flow. This helps to agitate the water and break up and clogs that may have formed. You can often program the length of time you want it to reverse, typically adjusted based on the amount and severity of blockages your system encounters. 

Most deraggers have several possible methods of functioning. The first is that they are set to reverse at set intervals. This interval is often set based on the typical experience of the installer and later adjusted based on how well it is working to clear the system. 

Many deraggers also have the capability to add digital monitors. These monitors allow you to monitor when a blockage may be forming and help to engage additional deragging cycles. They can send information back to a control system, trigger alarms, and be manually engaged. 

Anti-clogging with VFDs 

Over the past several years, variable frequency drives, or VFDs, with advanced deragging technology and capabilities have become more common. Many wastewater systems are already utilizing VFDs in their pumping systems, but have not explored using a VFD as the deragger. 

While not every line of VFDs has the capability, it is becoming much more common. VFD anti-clogging works very similarly to a deragger device. You can set time intervals for deragging, with variable time lengths of reversing and agitation. 

Deragger VFDs also have the digital monitors that are available in deragger devices, but they’re already built in. When commissioning the VFD, you run the pump and motor at various speeds to build a curve of the normal amperage at those speeds. The VFD uses that to learn what typical, unblocked usage looks like. 

Based on normal operation, whenever the VFD senses underload or overload conditions, it engages a deragging cycle to agitate and clear the blockage. You also can integrate PID controls to engage these cycles. 

Most VFDs also come with many options for BMS and SCADA connections and controls, meaning you can often manually engage anti-clogging cycles from a control room, or even at the VFD itself. 

Which Do We Recommend? 

Deraggers a great way to reduce the number of clogs that your wastewater system sees. They work in well systems, but the recent advances in VFD technology make them a much more attractive option to help improve your water system. Not only do you gain the same functionality and monitoring as a deragger, you also gain additional benefits outside of anti-clogging. 

VFDs save power consumption by reducing the electricity needed to run your motors and pumps. They allow your motors to start without the inrush that damages the motor, and some can help with soft pipe fill, or pre-charging. They can also help to avoid mechanical stress on your system by reducing the need to use check valves, as well as reducing water hammer and vibration. 

Case Study – Retrofitting a VFD with Deragging 

A wastewater system was performing upgrades to a pump station. This pump station had multiple pumping systems, with two VFDs needed to be replaced. As the team looked at upgrading VFDs, they knew that clogging was an issue that would need to be addressed. 

The pump stations within this system had always used deragging devices in the past to help clear any blockages. While replacing VFDs, they initially planned to install new deraggers. 

Our engineering team knew that this was the perfect opportunity to look at VFDs with built-in anti-clogging capabilities. The requirements for the system would already need full VFD control panels, so we went through a design phase to help implement the best solutions. 

The wastewater team specified that they wanted redundancy and reliability. Bypass and harmonic mitigation options were added to the system, and the communications were coordinated so that the entire system could be controlled remotely. They also wanted the ability to add an emergency stop and several manual controls to engage deragging cycles whenever the team felt it was necessary. 

After exploring the capabilities of the built-in deragging, the wastewater team decided that a VFD with this functionality was an acceptable technology to meet the specification. Our team moved forward with the engineering, production, and delivery of the panels. 

Our technicians helped to remove the old VFDs, install the new ones, and commission the entire system. This process included setting up the curves to detect overload conditions, designating regular intervals, and specifying when too many deragging cycles would send an alarm to the control room for further inspection. 

After commissioning the new VFDs, they went through months of observation and testing. The VFD deragging capabilities performed exactly as the wastewater team needed. They were able to simplify their system during the upgrade, while keeping all the functionality they needed to continue delivering water to their community. 

Let Us Help You 

When you start to look at your wastewater system as a whole, you want to reduce the complexity while increasing efficiency and reliability. While deraggers help to reduce clogs, VFDs perform the same role with more options included and increased advantages, all in one device. 

Most wastewater systems are already using VFDs. Being able to include this functionality with fewer devices is a benefit that we’ve seen help systems to get the best system with the least overall headache. 

Our teams of engineers and technicians have decades of experience working on water systems. We’ve installed hundreds of VFDs and have worked with deragging systems on many projects. We can handle installation, commissioning, and all the necessary programming and coordination. 

If your water system needs anti-clogging help, reach out to us and we’ll help you find the right products, get them installed, and program each one to the exact needs of your facility. 

One of the largest and most well-known convention centers in the world covers acres of land in a large city, but also has a hidden problem. The center is over 50 years old, and its aging electrical infrastructure draws a lot of electricity.

As in, an energy bill ranging from $4 million to $5 million every year.

This didn’t sit right with the building’s superintendent.

“I think that’s a little excessive,” he said. “Before we took over the building, it was a norm and that’s not a norm. You need to study that and bring that down.”

Something needed to change. Without an upgrade to make the convention center more energy efficient, its packed schedule of conferences, shows, summits, and other events could quickly dry up. That’s why the superintendent reached out to the Energy Management Corporation team.

Here’s how we helped him take control of the convention center’s energy consumption, all without disrupting any of the center’s 350 annual events.

Significant reduction in energy consumption

The superintendent’s primary goal was to reduce energy consumption and bring down that annual spend. To do this, we worked with his team to replace between 60 and 80 aging motors and install almost 100 variable frequency drives on his mechanical equipment.

The campus’ central facility alone has seven 1,000-ton chillers and over 20 pumps and cooling towers, and that was where his team wanted to start. Along with other energy efficiency initiatives, adding VFDs to that equipment has dropped the convention center’s energy bill by 8 percent. That adds up to over $300,000 annually.

BMS compatibility made easy

Going into the project, one of the main concerns was our equipment’s compatibility with the existing building management system. After all, if the VFDs can’t communicate with the system, there’s no way to control them and there’s no reason to install them.

“The venue is aged by the years and a couple decades of expansion, but they put in a BMS by the name of Siemens APOGEE,” the superintendent said. “That’s a very, very old system. It’s not even supported anymore from Siemens.”

In the end, he didn’t need to worry. Our team ensured all our drives came equipped with Siemens’ propriety means of protocol network communication – FLN communication. To do this, we sourced the communication cards, installed them before delivery and checked that the VFDs were compatible upon installation.

But for the convention center team, this was all so smooth and simple, they didn’t even realize the equipment was originally built without those communication cards.

Seamless installation with only one team

Throughout the sales process, the superintendent and his team worked closely with ours to solidify their goals for the convention center and chart the best path forward to reach them. But the partnership didn’t end after those initial conversations and the resulting sales. Our team also provided the labor for installation and startup, meaning the superintendent only had to work with one contractor he already trusted.

This streamlined communication and further lightened his very heavy load.

“It’s seamless,” he said. “I love the process. They come in, one team worked with my team, and when they come on site, the deliverables are 100 percent acceptable. They know what they’re doing. They listen to what I’m trying to do.”

Ready to reduce your energy consumption?

By upgrading aging equipment, installing VFDs throughout the convention center, and introducing other energy-saving initiatives, the property reduced its daily energy consumption by hundreds of thousands of dollars a year. Not only that, but the superintendent also gained a partner and trusted advisor – he never had to worry about the product, service or installation. He trusted us to take care of his campus, leaving him to do his job.

And with those savings, the convention center team is continuing to invest in the its energy efficiency. All while the new, more reliable equipment:

• Keeps the 50+ people on their team safe throughout installation and maintenance, thanks to its metal enclosure and safety devices

• Communicates easily with the existing BMS

• Supports the HVAC system and other mechanical equipment to ensure the campus is comfortable for the full events calendar

“It’s an event center, so it’s always occupied,” the superintendent said. “It’s big, huge, downtown, moving bodies – that’s the atmosphere, and approaching that without disruption? Not even allowing the visitors to know that we’re here or what we’re doing? We did that.”

The United States Environmental Protection Agency (EPA) recently released their proposal to regulate PFAS in water systems. Our team reviewed the release, attended the EPA webinar, and wanted to explain the key points.  

What is PFAS?  

PFAS is a type of synthetic chemical that is used in many kinds of production. They are often called “forever chemicals” because of how long they take to break down. You have most likely seen these used in nonstick cookware, waterproof clothing, and firefighting foam.  

The EPA is looking at six specific chemicals grouped under the PFAS category. The first two, PFOA and PFOS, are being treated differently in their proposal than the other four, PFNA, PFHxS, PFBS, and HFPO-DA (GenX chemicals).  

Most people won’t need to know what all of the acronyms stand for until the final regulation comes out, but it’s important to understand why the EPA is concerned about them.  

PFAS have been shown to have negative side effects. They build up in the body over time and can cause pregnancy complications, immune system damage, cancer, liver damage, and cholesterol issues.  

What is the EPA proposing?  

The EPA is proposing a regulation that will require three basic tasks from public water providers:  

1. Monitor the levels of the regulated PFAS chemicals  
2. Notify water users if levels exceed regulations
3. Reduce levels of chemicals to below regulation limits  

When the EPA proposes a regulation, they provide a Maximum Contaminant Level (MCL), the enforceable limit at which somebody can detect the chemical. The Maximum Contaminant Level factors in the ability to measure and the feasibility of attaining the correct level of PFAS chemicals.  

They also give a Maximum Contaminant Level Goal (MCLG) for what they would strive to get the contamination level down to. The MCLG is non-enforceable and is simply the best practice for optimal health.  

PFOA and PFOS want to strive for a goal (MCLG) of zero, but the EPA is proposing an enforceable MCL of four parts per trillion (4ppt).  

They have created a hazard index for the other four chemicals to measure them as a mixture. Both the MCL and MCLG are to keep the hazard index calculation at 1. The exact calculation for the level of each chemical and its weight in the hazard index is available on the EPA’s website.  

Who would the regulation affect?  

If the proposed regulation goes through, the main group it affects would be public water providers, although it may also affect manufacturers using PFAS. Public water providers are defined by the EPA as water systems that provide water to at least 15 service connections or 25 people. The EPA does not regulate private wells through this method, so they would not be affected.  

The EPA did release some preliminary estimates on the scope of the effect. Out of the 66,000 water systems that will be impacted, they expect about 5-10% to have at least one of the measured levels out of compliance.  

They estimate that the yearly cost for the requirements under this regulation will be between $772 million and $1.2 billion. However, that goes up by up to $60 million if water systems are required to dispose of PFAS.  

What is the process?  

The most important thing to remember is that this is a proposal only and still requires public feedback. The proposed regulation will be published online at www.regulations.gov under the Docket ID: EPA-HQ-OW-2022-0114. You can comment on the proposal for 60 days after publication.  

They also are still working to educate the public and answer questions. You can view the proposal here. They are holding a technical webinar on March 29, 2023 that you can register for here. They also are having a public hearing on May 4, 2023 that you can register for here.  

Although we don’t know the exact implementation plan yet, the EPA has stated that regulation such as this is typically accompanied by a three-year period where those affected work to come into compliance.  

Some funding will likely be available. The Bipartisan Infrastructure Law will give $9 billion, split between funds and grants to help water systems in small or disadvantaged areas. There’s also the possibility of about $12 billion in funding or aid through other programs and sources. The details for this will become more apparent as we get more detailed information about the exact regulations, processes, and available funding.  

What next?  

Water districts need to become more familiar with PFAS and how this will affect them. The EPA has released multiple sources ahead of finalizing this regulation. If you feel strongly or have comments about implementation or limits, provide comments to the EPA.  

We’ll stay on top of this issue and bring more updates to you as they become available. 

Since 1988, Energy Management Corporation has been working with a local university. This working relationship’s longevity is in part due to Bruce Tregaskis and his commitment to when the engineering department or HVAC shops need help. He’s been in the electrical industry for 43 years and when you need him, he will be there.

Over the years, the local university has been focused on its harmonics. If you are out of compliance with harmonics, utility companies are able to cut off power and charge fines.

Harmonics are a big enough issue that engineering and maintenance are concerned about what they are doing and how to alleviate the problem and minimize their impact.

Bruce has been pivotal in developing specifications for VFDs with harmonic mitigation on controlling the harmonics and getting them in compliance with the utility company. The specifications they work on focus on the performance that is needed to keep the university in line with utility requirements.

Because of the trust that has been developed, the local university has EMC as a preferred brand and is specified on campus projects.

“I would say as of today, we probably have 2,000 VFD devices on campus, and Energy Management Corp supplied 80% of those,” said the university HVAC shop manager.

EMC is here to deliver

Energy Management Corporation has always been there to deliver products or provide training.

“Whenever they need something, we jump,” Bruce said. “Delivery-wise, I will do whatever I have to do to get something when they need it.”

The university team agrees. “Whether it is a frequency drive or a large motor, we can usually get that delivered within a day. Many times, the same day.”

Bruce Tregaskis and the team at EMC have greatly impacted the university. When asked why how he’s been able to deliver such great quality, he said, “I’ve always had the philosophy as a salesman that I like to sell to friends, and these people are my friends.”

Downtime is one of the biggest issues that many on-site engineers, supervisors, and managers dread. Whether you’re a manufacturing facility, an extraction site, a packaging company, or a utility provider, downtime means lost production, lowered revenue, and high costs.  

When there is an unexpected failure, you not only have to pay wages and expenses while you’re down, but you may be looking at overtime for your employees or contractors to get you back up and running.  

Every minute counts. Having a critical spare plan means that extra equipment is nearby that’s ready to swap out and reduce your downtime. At the same time, having too many spares means you have over-invested in equipment and have increased upkeep expenses.  

How do you ensure you have the exact spare equipment and that it’s ready when needed? We’ve dealt with emergency electrical retrofits for decades, especially around aging infrastructure. We’ve seen that several best practices for your critical spare plan can help lower costs, reduce downtime, and prepare you for the next emergency.  

How do I identify critical processes and components?  

The first step to any critical spare planning process is to identify what spares you need to have ready and what you can go without. This process involves looking at your electrical system, determining the value of the spare to your process, and identifying possible failure points.  

Determine critical electrical system components  

One of the best places to start is to pull out your most recent electrical one-line drawings. If you need up-to-date drawings, you likely need to look into a service to do that and go through an arc flash study.

Looking at your one-line can help you identify points in your system with equipment that could be a lynchpin. If all electricity for your critical processes flows through one set of equipment, it’s worth identifying whether it’s worth stocking spares for.  

It would be best to also look at the production flow and processes. A manufacturing facility may have five production lines but they’re all fed by one conveyor belt. In that case, a failure on your conveyor means all production lines go down. Look for critical processes that would have an outsized impact.  

These critical processes often include transition points from one process to another. That may be a conveyor, a compressor, a pump, or something similar.  

Also, identify equipment that may be important for some other reason. Is it proprietary equipment that is important to have running? Is it essential for life safety, such as a generator for emergency lighting or fans for proper ventilation in a mine?  

Identify the value of spare availability  

While you’re looking at lynchpins that could bring your process down, look at areas that could cause the highest loss of revenue or emergency repair costs.  

You may have a particular piece of equipment that produces the highest product output or the most valuable components. While that equipment failing may bring down relatively little of the whole system, you will still lose extra money on revenue.  

One common issue is that last-minute replacements often lead to high logistical costs. You may have a massive motor and the logistics of moving the motor in a rush means extra crane charges, trucking expenses, or other issues. Identifying custom or large equipment that gets exponentially more expensive in an emergency helps you know that you should keep those products closer to hand.  

Some equipment may also take a lot of labor that is expensive to have wasted. You may see that certain equipment runs automatically while another piece of equipment takes three technicians to operate. In case of failure, you now have underutilized labor to account for as a cost.  

Find likely failures  

The frequency of failures is the last piece to look at. Even if the equipment is less valuable to your process or hard to replace, you can see downtime start to add up if it fails often.  

It may often fail due to factors internal to your facility. Does your facility have a demanding environment, such as being dirty or humid? Does it have extreme temperatures? Does it have bad power quality, such as harmonic issues, surges and transients, or power factor issues?  

You may also have processes that cause premature failures. For example, we’ve seen that motors close to crushers may fail prematurely due to excessive vibration, which can cause bearing damage. How you use or maintain the equipment could also affect its lifespan, such as whether you maintain it properly or tend to run it with excessive starts and stops or use high overloads.

External factors can also affect your equipment. You may be in a part of the world that is always hot, cold, humid, or dirty. You may have many surges/transients, harmonics, or other issues with your utility power. The demand in your market or industry could mean that your plant and equipment has to operate harder or longer than it was initially designed for. 

We often see that aging infrastructure is a problem with repeated failures. As electrical equipment ages, it may have components fail more often. A generator may have more engine failures, a VFD may have cooling system fans go out, or motors may start seeing more bearing failures. These failures can often result from aging equipment being subject to strenuous or repetitive use.  

How should I source spares? 

Once you’ve gone through the process above to identify which equipment may be critical to you, you can begin sourcing the spares to have ready for those processes. This process will involve looking at lead times, market conditions, logistics of delivery, and warranties.  

Identify lead times options  

Replacing equipment is one of many options when you have a failure. You may consider major repairs or even take the equipment out of service for reconditioning to avoid emergency failures. In these cases, you need to consider lead time for repair or reconditioning.  

We’ve seen that recent lead times mean that you need to re-examine many prior assumptions. A new motor may take a year to arrive, whereas a significant repair or recondition may take a few months. Many processes can’t afford to be down that long, so having a spare to put in place in case of failure will give you time to order new or repair the existing equipment.  

As you look at this, realize that you might not always be able to order a drop-in replacement, which may affect your timeline. If equipment is obsolete, you may see different brands, new dimensional layouts, the need for a mounting base or enclosure, conduit and wiring adjustments, or other issues. These adders may increase the lead time of the whole system.

Evaluate market and supply chain conditions  

More than ever, facilities are seeing that forces outside their control are affecting lead times and availability of equipment. VFDs, motors, generators, and many other products have seen widely fluctuating production and delivery times based on shortages of parts and labor.

When you’ve identified the spares critical to your site, identify the internal components to that equipment and which of those may have issues availability issues. It may be processor chip shortagesor raw steel material issues, but as part of your sourcing plan you should consider these issues.  

Identify shipping issues  

Shipping and logistics issues seem to be at an all-time high. To source products, we’ve seen an increase in international, large, and custom deliveries. Many facilities are having their first encounters with custom packaging, hotshot deliveries, or oversized load considerations. You should consider these issues and how they impact lead times and cost. 

We’ve also seen that cranes for offloading equipment at the site have delayed availability. Many sites are looking at getting spare parts on site or to a local vendor early and holding them where it’s easily accessible in case of emergency.  

Consider warranties  

As spares are brought in and stored, the warranty for the equipment is something to consider. Some brands have strict policies that the warranty starts at production or shipment, while others will allow a six-month delay before the warranty begins if you haven’t installed the equipment yet. Although you hope to never use a warranty, it’s important to identify what warranty you’ll receive before you order spares.  

How do I store and manage spares?  

Once you have your spares on order, you need to make sure you have a plan for storing and managing them, including where you’ll keep your spares, how you’ll maintain them, how you’ll manage your inventory, and what reports and trending you can do for improvement.  

Choosing a storage location  

The location of where you will store your spares is essential to make sure the money you invested doesn’t go to waste. Some facilities keep spares with a vendor or contractor, while others store them at their own production facility or warehouse.  

Wherever you store them, the environment needs to be within the manufacturer’s recommended storage conditions, often including a temperature-controlled building that is clean of contaminants like dust, dirt, moisture, and corrosive gases. For equipment like motors, you don’t want it too close to railroad tracks, crushers, or other major vibration sources that could damage the bearings.  

You also want a location close to your production facility and easily accessible in case of a failure. It needs to have the ability to be accessed not only at the right time but also by the truck or equipment that will deliver the spare. You also need to be able to offload and reload the items as required, including appropriate cranes, forklifts, and other equipment.

Maintaining spares  

For spares to be in working condition, you must have a maintenance plan. For some companies this means simply rotating equipment into service annually during shutdowns, but others may leave spares sitting in storage longer. The manufacturer will also have guidelines for this, but some best practices are universal.  

For VFDs, make sure you are cleaning and testing them, as well as reforming electrolytic capacitors. For motors, make sure you’re turning the shafts and performing testing. For generators, ensure that oil changes, fluid checks, and other preventative maintenance are happening as needed. If you need help maintaining your equipment, reach out to our team.

Managing inventory and assets  

Even worse than not having a spare at all could be thinking you have one available when you don’t. You could spend time driving to a storage site, searching a warehouse, and losing hours or days trying to locate a spare previously used on another application.  

No matter what system your company uses, make sure that you have a way to track spares on order, on site, and when they have been used. Verify the stock as frequently as needed and make sure that information is accessible in the case of a failure.  

Monitoring and reporting on usage  

When you have spares and track the usage, you can begin to improve your critical spare plan. As you start going through spares, you can see what you use and what you don’t. You may find your original plan was slightly off and needs readjustment. You may also start to identify areas of common failures or pain points you didn’t initially notice.  

If you notice a spare is not getting used, that doesn’t necessarily mean that you were initially wrong. Before adjusting your plan, make sure you go back and identify why somebody originally ordered the spare. It may not be a common failure, but could be critical to your processes and worth having a spare even if failure is unlikely.

Let us help you plan  

Developing a plan, evaluating your system, sourcing spares, and storing the spares can seem like a lot to manage. For many of our customers, we’ve been able to help with this process. We can help with every step of the process, including storing and maintaining them at our facilities when it makes sense.  

If you have questions or want help with your critical spare plan, reach out and let one of our experts help you.

Over a million barrels of nuclear waste from the Manhattan Project are stored in tanks located at the 200 East area of the Hanford Nuclear Reservation near Richland, Washington.

But they can’t stay there forever. Especially after an underground tank started leaking.

The U.S. Department of Energy started the radioactive waste treatment plant project more than 20 years ago and contracted with Bechtel to help run it. Plant personnel convert nuclear waste from its raw liquid form into a solid trapped within glass.

This process, called vitrification, allows radioactive material to be safely stored for many millennia.

Breakdowns and outdated equipment create catastrophic downtime

To perform vitrification, nuclear waste is poured into a large box. Bubblers and air pressure stir the waste as it dries. Then silica sand and other glass-forming ingredients go into the mix, which is melted down at temperatures of around 1,000 C.

This molten mixture is poured into stainless steel containers, where it hardens into glass with the radioactive waste safely trapped within.

The plant’s cold crucible induction melter is the heart of the vitrification process. The melter generates intense heat, so the cooling system is critical for function and safety.

Unfortunately, the 800-horsepower vertical shaft motors that serve the huge cooling tower malfunctioned in early 2022, leaving the mechanical team scrambling to find a solution. Harmonic issues in the bearings might’ve caused shaft wobbling that damaged the impellers and left the motors inoperable.

The motors were shipped out for repair. But in the meantime, Bechtel was on a hard deadline to get the melter working again. If they couldn’t, they risked defaulting on their DOE processing contracts — and halting the progress of harmful waste reduction.

Bechtel subcontracted with another company to fix the issue. They provided PCW pump skids to get plant cooling water flowing again. But the team quickly realized that the system’s VFD control panels were woefully outdated.

The subcontractor got in touch with their equipment vendor. And they subcontracted Energy Management Corporation to provide a control panel to operate two 500-horsepower, 480-volt, three-phase motors.

Collaborative design and personal service provide rapid delivery

Mike Weitzel was charged with leading the project. The senior engineering electrical tech specialist had worked with Bechtel for more than 13 years, and he knew just what he was looking for.

Mike wanted two 500-horsepower motors fed by large generators with a UL 508A industrial control panel. But he needed Energy Management Corporation to navigate industrial supply chain issues and expedite equipment delivery.

And he got more than he expected.

Mike visited Salt Lake City to ensure EMC had the capabilities the project demanded. He met the company leadership who led him on a facility tour. Then they reviewed the project engineer’s designs and worked through some initial issues together.

He left Salt Lake City confident that EMC’s facilities, expertise and personal service were exactly what Bechtel needed in an energy partner.

“I could see that they were a great resource for a nuclear plant or any large facility with pump stations,” he said. “Their CEO got with me to resolve some of the issues we had in the control panel. I was very impressed with Steve. He took a personal interest and showed me around the facility. The experience and knowledge they have with adjustable speed drives is, I think, second to none. I would put them against almost any company I’ve ever seen.”

Mike was especially impressed with EMC’s knowledge of harmonics, such as how to mitigate harmonics that can affect the motor shaft on large medium-voltage motors. That might’ve caused the plant’s initial motor failure, but it won’t be a problem anymore.

“I was grateful, thankful and very impressed,” Mike said. “They got our work completed within a short order and made it happen for us. I’m really impressed with the control panel. The workmanship and engineering were solid. The materials used were good quality, and I was very pleased. It’s a really good, serviceable unit.”

Expert execution and reliable service create satisfied customers

Hanford Nuclear Reservation’s new industrial control panel for their 500-horsepower motors arrived on expedited delivery.

Each motor is independently powered from the generator. EMC customized the system to include a requested service entrance that provides maintenance access to prevent future downtime.

“I was very pleased and very impressed with their professionalism, with how gracious all of them were to me as a client, and their delivery of the product,” Mike said. “They expedited the delivery and made it happen for us when we needed it, so I could not have been more pleased, honestly.”

The Hanford Nuclear Reservation now has the system it needs to reduce the environmental risks of radioactive waste. And Bechtel knows they can count on EMC to help with any new emergencies.

That’s why Mike’s still singing EMC’s praises. “I would highly recommend them to anyone, especially those who have a big municipality, a farming operation, a mining operation, nuclear facilities, they should become good friends to EMC,” Mike said. “They will help when customers need it.”

Ensure the best for your next project

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Standby emergency generators are an excellent tool for many companies who want to maintain power when utility systems fail. When looking to install a generator, the scope often turns into a full turn-key installation project. 

When the scope grows and you now have a full construction project on your hands, what are the things you need to consider? We’ll walk through some of the most critical principles and roadblocks we’ve seen with these generator installation projects. 

Generator Specifications

The most important part of your generator installation is the generator itself. If the generator doesn’t work as you need it to, then all your effort will be wasted. When specifying a generator, there are many things to consider. 

Size

The generator needs to be sized large enough to handle the loads in the way you need. This is often measured in watts, kilowatts (kW), or kilovolt amps (kVA), which measure the energy the generator can output. 

The sizing of the generator is based on the loads you need to run. Loads like lights, computers, servers, and motors must be considered. For motors, also consider how it is started (simultaneously or sequentially) so you know the initial draw. 

Look at what loads need to be run together as well as the starting order. If multiple motors start at once, you need a more significant generator because of the initial pull. But if you start your motors in a sequence, you can often save money and downsize.

One great tool to help calculate these loads and what size generator you need is Generac’s Power Design Pro. This program walks you through putting in your loads and the sequence to calculate the required variables.

Voltage

What voltage does your facility need to run? It could be 120V, 240V, 480V, or above 1000V. For lower voltages, is it single- or three-phase? Using a generator with the wrong voltage could cause your system to malfunction or fail.

Fuel

The fuel that you will run the generator on is essential to specify. Diesel is a common option when there needs to be fuel stored on site. Natural gas tends to run cleaner and requires less maintenance in the long run; although it may require a higher initial cost in larger generator sizes, it can often win out when looking at the total cost of ownership. Propane is often the necessary fuel in remote locations. 

When looking at what fuel you will use to power the generator, also look at how you would replenish that fuel and what costs the fuel might bring. There are upfront costs to consider, whether running gas lines or purchasing tanks, as well as maintenance costs, such as diesel fuel polishing, testing, and refueling. Diesel is also prone to wet stacking, which can cause generator performance issues.

It also helps to look at how you would keep the generator fueled and running in case of a long-term outage, such as bringing in diesel fuel by truck.

Sound 

The engine, exhaust, and generator components make noise, similar to a car or large truck. Some generators are in areas surrounded by other heavy industries where noise isn’t a concern. For a generator at a pump station in the middle of a neighborhood, however, the weekly generator exercise and any other needed use could lead to issues for the surrounding environment. 

Some generators are placed inside a building, often in a basement or on a roof. In these cases, the noise may affect the rooms and floors nearest to it, which may need to be mitigated. 

Specifying a set decibel or dBA can help ensure that your generator has as little impact on the surrounding environment as possible. The system may mitigate this by building a level of sound suppression into the enclosure, constructing sound walls, or creating physical distance. 

Temperature 

Just like trucks that struggle to start on a cold morning, you should consider what problems temperature might lead to on your generator. Consider adding block heaters if you have a generator going into a cold environment. If excess heat is an issue, consider what cooling may be necessary. Block heaters and proper heat exhaust are the most common temperature control methods we’ve seen used to help with these issues. 

We’ve also seen problems in the past where not enough clearance is given to the generator’s exhaust. This leads to warm exhaust air recirculating into the air intake, overheating the engine and leading to alarms, shutdowns, or damage.

Weather Protection 

If your generator is placed outside, you need to be able to protect it from the elements. You may encounter rain, wind, snow, or other common issues. Similar to temperature, these factors are dealt with quite often and are easy to deal with if they’re considered upfront. Increasing the enclosure’s protection level helps keep the generator running longer. 

Elevation 

While considering your environment, determine the elevation your generator will be operating at. Higher elevations have thinner air, which can affect the cooling and efficiency of your motor. A generator’s engine may need to be derated (or oversized) to get the same output at a higher altitude.

Seismic 

Seismic requirements may also be a factor in some areas. If there is a seismic mitigation requirement, extra thought must go into the generator’s design. You may see different mounting to the ground, additional clearance, or other considerations. 

NFPA 110 

NFPA 110 is the National Fire Protection Association standard 110 for Emergency and Standby Power Systems. In some situations, a generator may be deemed “life safety.” This means an outage would risk the lives of those whose power was lost. This is typically associated with healthcare facilities such as hospitals, surgery centers, and assisted living facilities. 

When this is needed, additional requirements include on-site fuel storage, docking stations for backup during maintenance, and load banking during maintenance. It can also include working with authorities having jurisdiction (AHJs) in order to know what the specific local requirements and interpretations will be.

Electrical 

Once the right generator is specified, you need to consider how it will interact with your existing electrical system. The purpose of a generator is to supply electricity, which makes this step a crucial part of your project planning. As you look at electrical changes, make sure to evaluate what permits are needed in your area for the work you do.

Wire and Conduit 

Wire and conduit are how you will get the electricity from your generator to your system. If there isn’t a plan for how that will be prepared and sized appropriately, your generator will never get the power to the devices that need it to operate. Accurate one-line and electrical diagrams along with field verification will help to make sure that everything has the backup power it requires. 

VFD and RVSS Interactions 

Variable frequency drives (VFDs) are a common tool to control the speed of motors. You can learn more about VFDs and how they work here. Reduced voltage soft starters (RVSSs) are also electrical equipment that can help a motor start in a more controlled manner, and both are great tools to reduce the requirements of a starting motor. 

VFDs create harmonics and are often accompanied by capacitors and other devices, which can cause power factor issues with a generator. Evaluate what controls and devices like these are on the load side of the generator that may cause problems. Look for VFDs, soft starters, capacitors, and other devices that may affect harmonics, power factor, or other issues. 

The Power Design Pro tool is excellent at helping to calculate how harmonics and other loads can affect the generator and what sizing would be changed based on motor starting methods.

Automation and System Integration

If you have building automation or a SCADA system, you will want to ensure the devices needed to make the generator compatible are included. Even if they are, you need the connection to the generator to ensure it can communicate. Make sure that controls are run to the generator, and also account for Wi-Fi, internet, Bluetooth, or any other needed technology.

Docking Stations

If your life safety generator is unable to run due to maintenance or repairs being done, NFPA 110 will require that you still have back up power during the time the unit is down. The most common way we see this addressed is through a docking station. This allows for a portable generator to be connected and back up your facility during maintenance or repairs. Make sure to account for this and comply with those requirements.

Civil

Civil requirements are important to ensure that your generator installation is safely designed and will remain stable and reliable for as long as possible. As you look at civil changes, remember to determine what permits need to be obtained.

Concrete Pads

Industrial generators should be installed on a level, stable, strong concrete pad. Even mobile generators should be placed somewhere they are stable and secure. As you design a concrete pad, consider the generator’s weight and placement. Look at the specifications and drawings, so that conduit and other stub-ups are located appropriately. If you have remote fuel storage, consider how that fuel delivery system will affect the pad.

With the pad, also take into account maintenance and walkways. You may need to extend the pad past the edge of the generator enough that technicians and maintenance personnel have a stable ground to work from. Suppose you have a tall generator, or it’s on top of an elevated diesel fuel tank: you may also need a walkway installed so that the filters, controls, and other necessary components are easily accessible for maintenance or troubleshooting.

Lastly, consider how the generator will be placed on the pad. Will a crane or forklift be needed to place the generator? Will it be able to access the pad safely and accurately?

Walls, Fences, and Bollards

Walls may be required in some situations. When dealing with sound requirements, you may need a sound wall to reduce the dBA in specific directions. There may be local ordinances or requests that the generator is hidden from view by a wall or fence, or you might just need to restrict access to the generator. 

If your generator is surrounded, evaluate how you can still access the generator for work. Make sure that the keys or codes are accessible in case emergency access to the generator is needed. 

With walls and fences, you also need to consider how much space the generator needs to function correctly, including exhaust venting, room for air intake, space to refuel, and other requirements. Leave enough space for electrical and OSHA requirements on clearance, plus what is needed to safely and efficiently maintain or evaluate the generator. 

One common way to protect the generator while maintaining accessibility is to surround it with safety bollards. These may be required for specific uses and can vary in color, withstand ratings, height, and other requirements. Verify that they don’t interfere with the generator’s access if installed. 

Secondary Containment 

Double-wall fuel tanks accompany most diesel generators. In some cases, secondary containment could be required, and we’ve seen this often required for sites near rivers, streams, or other environmentally-sensitive locations. 

Secondary containment is usually built with cement, metal, or plastic walls surrounding the generator. As with other civil considerations, ensure appropriate access for maintenance and compliance to relevant standards. 

Safety 

Generators are essential to maintaining safety on a site, but you also should consider how to keep those safe who might be near the generator.

Emergency Stop 

An emergency stop, also known as an e-stop or kill switch, is a button that can be used to shut down the generator in an emergency. These are typically easy to see and should be labeled clearly in accordance with electrical, local, and site requirements. They should be easily accessible. If you build a wall or fence around your generator, it may need to be located in an unlocked location, such as located near your transfer switch or other controls.

Often we see that emergency switches are protected from accidental presses while still being easy to access in emergencies. These may include unlocked covers or “break glass” style setups. When an e-stop is needed, coordinate with what local and other regulations require.

While looking at your emergency stop and labeling, you should also look at your ATS. Is it clear where this is to anyone working on the generator? You may consider posting a sign near the generator where to find the ATS if it’s not within sight and obvious.

Warning Signs, Labels, and Marking 

Depending on electrical, local, OSHA, and site requirements, anything that produces noise, has moving components, or deals with electricity may need to be labeled. Consider what size the labels should be and where they should be posted. You may also need to mark the ground, wall, or fence surrounding the generator or control approach areas and other distances that should be observed for safety.

Commissioning

To verify that a generator installation project will have the desired results, you should consider how you commission the generator system.

Commissioning Plan and Warranty 

Commissioning plans depend on the manufacturer and who you bought the generator from. If you buy from a supply house, you may need a third party authorized by the manufacturer to commission and start up the generator. If you buy from a generator manufacturer’s direct distributor, there is a good chance they also have a service team who can complete this work. 

Authorized commissioning is usually necessary for the warranty on the generator and ATS to be registered and valid. In many cases, a generator manufacturer will require that their authorized team be there for the first time the generator is run, so be careful to read through the warranty requirements. 

Verify that you have appropriate access for the commissioning. Not only do you need the space to do it, but you also need to make sure that the commissioning technician has needed keys and codes, or has someone to supply those on site. 

Suppose you are conducting a load bank with the start-up, whether for NFPA 110 requirements or simply as a best practice: verify that the system is ready for that and appropriate time is allocated. In order to comply with NFPA 110, load banks often take hours. Your chosen factory-authorized commissioning team will be able to walk you through what is needed based on your circumstances.

Ongoing 

As you plan for a generator installation, you should look ahead to what the ongoing use of the generator will look like. The turn-key installation is only the beginning of the generator’s life at your facility, so you should be prepared for the long term. 

Maintenance Cost and Commitment 

When evaluating generators, look at the cost of maintaining them. Evaluate the manufacturer’s suggested maintenance schedule and what parts will be needed periodically. This includes oil filters, air filters, batteries, and other components. You will want to look at fuel polish, refueling, and similar costs. These will typically be lower on a natural gas generator than a diesel system as you would have reduced fuel maintenance needs. 

Depending on NFPA 110 requirements and other preferences, you may also need to account for load banking periodically. This will help to prevent wet stacking, especially in diesel generators. 

Look at the local support that can supply this maintenance, whether it’s your team or a local service company. The distributor for the manufacturer often has a factory-authorized team locally who can help. It’s important to consider how many local, qualified, 24/7 technicians are available to support problems. 

Reliability 

When you look at a generator system, look at the reliability. Most manufacturers will have data on a system’s mean time between failures (MTBF), which can indicate reliability. You may also want to look at the reliability of other integrated systems, such as your main utility or the fuel supply. 

Monitoring Capability 

When looking at the long-term usability of a generator, analyze how easy it is to monitor and detect problems with the generator. Determine whether it can integrate into the systems you currently have existing. What capabilities does the generator offer if you need emails, texts, or audible alerts? How easy is it to use and diagnose problems through the controller? 

Redundancy and Additions 

When you design your system, consider what happens in a failure. Is there redundancy? How safe is your system if you have more capacity than you need or just have generators with built-in redundancy? 

We like to use Generac Gemini generators as they have two 500kW engines making up a total of 1MW of power, meaning a complete engine failure still leaves you with 500kW of power to back up your most critical loads. These can also be paralleled together to add more capacity if needed. This provides a high amount of redundancy and the smaller engines often come in at a competitive price point.

Also, consider future growth. Can the generator you install be paralleled or added to later if your system needs to grow? What would that look like? 

A generator turn-key installation can be a big project with many components. While there’s a lot to consider, breaking it down into sections can help to plan the different stages. 

As always, the experts at Energy Management Corporation are happy to talk through your specific project and needs. Whether it’s a complete turn-key installation, a retrofit, or some other generator project, contact us to discuss your questions. 

Emergency standby generators are an essential piece of equipment for many businesses as they keep vital processes up and running. Some areas, like Las Vegas, are prone to a big issue for generators: heat. If you’re looking at buying, installing, or maintaining a generator in Las Vegas, there are several things to consider to ensure that your generator lasts longer and works when needed.  

What causes a generator to overheat? 

Several issues could cause a generator to get too hot. These range from internal to environmental problems, but all overheating matters should be examined. 

Generator sizing 

If your generator is consistently overheating, you may want to evaluate whether it’s large enough for the demands. A generator may initially be correctly sized, but as new motors or other loads are added, the generator may not be enough. You may have also changed how you bring your loads up, bringing more on at once and overloading the generator. 

Look at elevation. Las Vegas is about 2,000 feet above sea level; many surrounding areas may get higher. The air becomes thinner when the elevation increases and many components struggle to cool themselves. Make sure your generator was properly de-rated (or upsized) for the elevation. 

Ambient conditions 

The next most obvious place to look is the ambient conditions. Is the temperature warmer than what was initially expected? Is the generator not in the shade that was expected? Is there more humidity or some other issue? You may even want to evaluate the paint color. If the generator has been repainted or is a darker color, it may attract more sun and heat than was initially planned.

Environmental contamination 

Desert installations like Las Vegas are likely to run into environmental issues that can make a generator run hot. Dirt, dust, and debris on components and the enclosure can cause problems. When there is contamination, the generator and its components don’t dissipate heat the way they’re designed to. Keeping your generator clean and planning for locations that stay cleaner can help it to run cooler. 

Electrical issues 

Generators are made to produce electricity and therefore, have many electrical components. If there’s damage or a failure in any of those components, you may get warps, hot spots, or other issues. Verifying the health of the rotor and other issues can help identify the cause of heat. We recommend having a rotor inspection done by a local expert, and they can tell you whether a repair, rewind, or replacement is needed. 

Cooling system issues 

Rather than producing too much heat, sometimes the issue is that the generator isn’t correctly cooling itself. Fans, blowers, filters, and exhaust systems must be inspected for damage or blockages, and any of these could prevent proper airflow that would cool the generator. 

One issue we’ve seen too often is that the needed clearance around intakes and outlets/exhausts is not accounted for. We’ve seen generators installed under ceilings with not enough clearance, which causes the hot exhaust to cycle back into the cool air intake. In the best cases, this leads to an alarm that prevents the generator from running. In the worst case, it could lead to damage or failure which becomes a more significant issue to fix.

Coolant and oil issues 

Generators have internal systems to control the engine’s temperature and components. These coolant and oil systems have pumps, reservoirs, hoses, clamps, and other parts that can fail. These parts, as well as fluid levels and cleanliness, should be regularly checked. 

Monitoring issues 

If your generator is set to monitor for heat, verify that the monitors and sensors are functioning correctly. If the temperature is being misread or not being communicated correctly, the other systems may not receive the message to begin cooling. 

How do you fix heat issues? 

Once you’ve identified that your generator is overheating, what do you do about it? The key to fixing heat issues is to identify and correct them before they get too severe and cause damage, leading to more serious repair or replacement. 

Make sure the generator exercises 

Generators should often exercise to make sure that they are operating correctly. These exercises are often where overheating alarms arise, giving a chance for corrective action to occur. They also ensure that all components move regularly and work as they should. 

Conduct thermography evaluation 

Using an IR camera to take thermographic images helps to identify hot spots and other issues. These can alert you to the issues discussed above and help you plan for potential repairs or failures. 

Conduct preventative maintenance 

Every site with a generator needs a clear, routine maintenance schedule. We recommend two services per year as a minimum. Every year you should change oil, check hoses and belts, and evaluate components. When replacing oil and other filters, write the date of the change on the filter. Record all work done and document conditions with pictures. 

Between each service visit, you should have an expert come by to inspect the generator. Generator technicians should inspect belts for wear, hoses for cracks, clamps for tight fits, fans for proper operation, and the overall generator condition and cleanliness. A site evaluation should document any changes that might affect the heat. These could include items blocking air intake clearance, other construction that might change the load, and anything else notable. 

If you have many sites around Las Vegas, the state of Nevada, or even farther reaching, develop a geographic route that makes sense. Even though it’s maintenance, you still need to plan for the oil, filters, and other components you need to bring. This is where it often makes sense to hire a company like Energy Management Corporation to help. We can plan these routes with other local generators and conduct other on-site services. Combining a generator maintenance visit with VFD maintenance, motor vibration testing, or other services saves travel time and expense.

This is the third installment of the five-part guide. If you want to learn about the other common causes of motor failure, read more about failures involving bearings, winding, rotor bars, and shaft coupling. 

External conditions are tied for the second most common reason for motor failure. As a motor owner, not only do you have to worry about what condition the motor itself is in, but the environment it is in as well. Knowing how external conditions can damage your motor as well as how to prevent the damage is crucial in maintaining the longevity of the motor. 

Negative external conditions account for 16% of all motor failures. 

The most common external condition issues include:  

• Overheating
• Humidity  
• Contamination  

Overheating 

Some motors can’t take the heat, so don’t put them in the kitchen. If the temperature of your working environment isn’t within the motor’s tolerances, you’re going to have problems. 

To prevent overheating, select a motor designed for the heat it’s going to face. You’ll need high-clearance bearings and an insulation system that offers high levels of protection. Additionally, you could add features like constant cooling fans, cooling coil radiation, and enclosures that will help beat the heat.  

Properly maintain your motor cooling system or it could work against you. Broken fans, clogged vents, or blocked or damaged cooling fins can cause excessive heat buildup and quickly degrade internal wiring insulation. You’ll know you’re too late when you smell the insulation burn up. 

Humidity 

In humid environments, moisture from the atmosphere can enter the motor. Electricity and water are a bad mix! The combination can damage the internal winding and cause corrosion. We’ve also seen folks cause this type of problem by trying to clean out motors with pressure washers.  

Problems with humidity can be abated by opening drain hole plugs, fitting anti-condensation heaters, and utilizing additional corrosion protection (i.e. enhanced paint systems or coatings). If you cannot completely seal against moisture ingress, ensure that the breather plugs are fitted and kept clear so moisture that enters can drain away. 

Contamination 

Any foreign particles that find their way into the motor can cause irreparable damage as they settle into the windings and cause shorts that degrade the insulation.  

It is important to do everything humanly possible to keep any contamination away from the motor to preserve its longevity. If you can’t control the amount of dust in the air, special enclosures with built-in fans can help clear particles from the windings and limit the amount of dust that can reach them. 

Want to learn more about motor failures and solutions? 

There’s an electric motor system for almost any environment if you know where to look. Find the right model and accessories to face the elements and keep your applications powered in any weather. 

You also can read more about common motor failures involving motor bearings, winding, rotor bars, and shaft coupling. 

If you have any questions about how to meet the demands of your motor’s working environment, contact a sales engineer at VFDs.com. You also can email us at info@vfds.com or call 1-855-207-1721.